When it comes to mailings, are you looking to reduce costs for materials, labor and postage? What if you could also increase productivity by reducing processing time? All of this is possible with pressure seal technology, which allows you to create, process and deliver forms without an envelope. In fact, by eliminating the printed envelope — and the related folding, stuffing and gluing — from the process, pressure seal is a more cost-effective, green alternative for office mailings.Learn more about how pressure seal forms work and how they can improve your organization's efficiency.What Is a Pressure Seal Form?You've definitely seen pressure seal mailers before! They are sealed on the sides and have perforations that allow you to open the mailer. Like this:[Video Slideshow]How Is a Pressure Seal Form Created?Pressure seal requires a one-page, self-sealing document, such as a form or a check, and a folder/sealer machine to fold and seal the document. The pressure seal form can first be printed on an office laser printer and then fed through the folder/sealer machine. While different types of mailers require liquid or heat for sealing, high amounts of pressure are what seal these kinds of documents. Folding aligns patterns of cohesive applied to the edges of the form during manufacturing. The cohesive is activated by the folded form that passes through a series of sealing rollers that apply pressure, creating the seal.What Is a Cohesive?Unlike standard adhesives, a cohesive requires that two patterns be placed on top of each other to create the bond. Cohesives adhere only to each other and only when very high pressure is applied. This technology alleviates the risk of damaging a printer with a more traditional heat or water-based glue on the form. Pressure seal forms emerge from the folder/sealer securely sealed and ready to mail. In fact, this security is one of the reasons that pressure seal forms have significantly higher open rates than a traditional direct mail piece.Benefits of Pressure Seal Mailers A few of the key benefits of using pressure seal mailers include:Cost savings on envelopes: With no need for printed envelopes, businesses can reduce material costs. These mailers also save money on labor expenses by reducing the manual work required to prepare envelopes for delivery.Processing time: Window envelopes can result in processing delays and delivery problems. With pressure seal mailers, addresses are more visible and readable for postal processing systems, ensuring more efficient delivery.Operational efficiency: In addition to improving postal processing times, pressure seal mailers can reduce the time spent on document processing and mailing. Specialized folding and sealing machinery allows staff to dedicate more time to essential tasks.Improved document security: A pressure seal mailer is a secure, self-contained piece of mail, meaning only the recipient can open it. A strong, cohesive seal makes seeing signs of tampering easy. These qualities make pressure seal mailers especially beneficial for secure communications.More eco-friendly than traditional mailers: Cutting out the extra paper, glue and folding makes pressure seal mailers a better green alternative to traditional mailers.Professionalism: Pressure seal mailers lend a more professional look to your organization's communications, improving your image and reputation.How to Get Started With Pressure Seal MailersWhen you're ready to implement pressure seal mailers at your organization, follow these three essential steps:1. Choose the Right Pressure Seal FormsWhen selecting a pressure seal form, you have a few choices for the type of form and fold configuration:Z-Fold: As the most common type of fold for things like checks and tax forms, the Z-fold folds the document into three even horizontal sections that form a Z-shape when opened.V-Fold: Using a single horizontal fold, the V-fold configuration is great for forms and mailers.C-Fold: Similar to the Z-fold, the C-fold configuration consists of three horizontal sections, but they open up in a C-shape. They're great for promotional mailers.Custom: If you have a special configuration in mind, you can design the specific fold and dimensions you want.2. Select a Compatible Pressure Seal MachineBecause different pressure seal machines have differing capacities, choose one that suits your needs. For instance, if you need forms smaller than 14 inches at a lower volume, a desktop model could be right for you. Meanwhile, higher volume applications requiring forms up to 25 inches long would better suit a floor model.Similarly, the type of printer you have will determine the kinds of mailers you can produce. Simplex printers print on one side of the form, while duplex printers can print on both sides.3. Design Your Form for Optimal Pressure SealingWhen thinking of form design, you have options for both simplex and duplex printers. Although simplex printing could limit your design, you have options — Z-folds allow for two panels, while C-fold configurations with a window would give you more space for your design. Duplex printers work well with most form types and allow for two-sided designs. When designing your form, take the following considerations into account:Sealing patternFold placementsAdhesive placementPerforationsDoing a test run of your design before running a larger batch is a good idea to ensure everything is in the right place.What Can I Send With Pressure Seal Mailers?Examples of documents you can send using a pressure seal include the following:ChecksUtility billsPIN informationTest resultsInvoicesMedical billsTranscriptsTax formsPast due noticesMarketing piecesStatementsRecall noticesRegardless of what you’re sending, ULTRASEAL self-mailers offer a more cost-effective and time-saving solution to traditional envelopes or other types of mailers. RELYCO Can Fulfill All Your Pressure Seal NeedsRELYCO can fulfill all your pressure seal requirements, from printing equipment to forms and checks. You can shop our selection of ULTRASEAL forms and ULTRASEAL checks for your business's needs. For additional information on pressure seal forms and equipment, watch this video and contact us with questions.*This blog post was originally published on November 8, 2010. It was updated and republished on Month Day, 2025.